Automatic Skive Filling System

Abstract

A method is provided for automatically filling a skived region on a tire carcass, the method including: analyzing, by a computer system, a surface of the tire carcass using a sensor, identifying, by the computer system, a first skived region of the tire carcass, determining, by the computer system, whether to perform a filling operation to fill the first skived region, communicating, by the computer system, in response to determining to perform a filling operation, a location of the first skived region to a filling device, and filling, by the filling device, the first skived region.

Description

[Technical Field]

[0001] FIELD OF THE DISCLOSURE This disclosure relates to tire processing, including tire retreading. [Background technology]

[0002] Retreading tires provides an economical way to further use a tire casing after the original or retread tread has worn away. For example, one retreading method, sometimes called cold-process retreading, involves removing the worn tire tread from a used tire. This creates a buffed, treadless surface around the circumference of the tire casing onto which a new layer of tread can be adhered. Other methods, such as mold-cure retreading and hot-cap retreading, can also be used. Repairing a tire without retreading is another way to get further use out of the tire.

[0003] The tire carcass is then typically inspected for damage, some of which is skived and filled with repair rubber, while others may be severe enough to require the casing to be discarded. A layer of cushion gum may then be applied to the back, i.e., the inner surface of the new layer of tread, or alternatively, a layer of cushion gum may be applied directly to the sticky surface of the tire carcass. Cushion gum is a layer of uncured rubber material. The cushion gum and tread may be combined and applied around the circumference of the tire carcass to create a retread tire assembly for curing. Alternatively, a length of tire tread may be wrapped around a tire casing that already has cushion gum applied. The cushion gum may form the interface between the tread and the tire casing during curing. Summary of the Invention

[0004] A new tread for a pre-cured retread application is typically molded as a single piece with a tread pattern on one side. Such a tread is sometimes called a pre-cured tread. The pre-cured tread typically has a width corresponding to the width of the crown of the casing and is cut to a length corresponding to the circumference of the casing. Alternatively, a replacement continuous tread is applied, and then the assembly is subjected to a roller pressing process, commonly called stitching, to force air out from between the tread strip and the casing.

[0005] After assembling the tire carcass, cement, cushion gum, and tread, the entire retread tire assembly may be placed within a flexible rubber envelope. An airtight seal may be created between the envelope and the bead of the tire. The entire envelope tire assembly may be placed within a curing chamber and subjected to a vulcanization process that bonds the materials together.

[0006] Because the remediation steps are time-consuming and labor-intensive, new technology is being introduced to reduce the time required to complete the steps without impacting the quality of the remediation. In addition to reducing the time required for each step, many steps are performed manually. Therefore, it is desirable to improve the process to automate and standardize the steps.

[0007] At least one embodiment relates to a method for automatically filling a skived area on a tire carcass, the method including: analyzing, by a computer system, a surface of the tire carcass using a sensor; identifying, by the computer system, a first skived area of ​​the tire carcass; determining, by the computer system, whether to perform a filling operation to fill the first skived area; communicating, by the computer system, in response to determining to perform the filling operation, a location of the first skived area to a filling device; and filling, by the filling device, the first skived area.

[0008] Another embodiment relates to a system for automatically filling skived areas on a tire carcass, the system including a scanner, a filling device, and a controller communicatively coupled to the scanner and the filling device, the controller comprising a processor and a memory configured to store instructions that cause the controller to perform operations including: analyzing a surface of the tire carcass using the scanner, identifying a first skived area of ​​the tire carcass, determining whether to perform filling of the first skived area, and instructing the filling device to fill the first skived area.

[0009] Another embodiment relates to a non-transitory computer-readable medium configured to store computer-executable instructions therein that, when executed by a processor, cause the processor to perform operations including: analyzing, by the processor, tire carcass surface data received from a scanner, identifying, by the processor, a first skived region from the tire carcass surface data, determining, by the processor, whether to perform filling to fill the first skived region, and in response to the processor determining to perform filling, instructing a filling device to fill the first skived region.

[0010] This summary is illustrative only and is in no way intended to be limiting. [Brief explanation of the drawings]

[0011] The present disclosure will become more fully understood from the following detailed description taken in conjunction with the accompanying drawings, in which like reference numerals refer to like elements and in which: [Figure 1] FIG. 1 is a block diagram of a tire repair system according to an exemplary embodiment. [Figure 2] FIG. 2 is a process diagram of a carcass repair system according to an exemplary embodiment. [Figure 3]FIG. 3 is a process diagram of a method for retreading a tire, according to an exemplary embodiment. [Figure 4] FIG. 4 is a process diagram of a sequential method of the tire carcass repair process of FIG. [Figure 5] FIG. 5 is a process diagram of the tire carcass repair process method of FIG. [Figure 6] FIG. 6 is a cross-sectional view of a tire carcass according to an exemplary embodiment. [Figure 7] FIG. 7 is a cross-sectional view of the tire carcass of FIG. 6 after filling. [Figure 8] FIG. 8 is a process diagram of a fill determination method according to an exemplary embodiment. [Figure 9] FIG. 9 is an illustration of a robotic arm positioning a tire carcass on a mandrel according to an exemplary embodiment. [Figure 10] FIG. 10 is a diagram of a scanning device in accordance with an exemplary embodiment. [Figure 11] FIG. 11 is an illustration of a skiving device according to an exemplary embodiment. [Figure 12] FIG. 12 is an illustration of tool selection in accordance with an exemplary embodiment. [Figure 13] FIG. 13 is a side view of a filling device according to an exemplary embodiment. [Figure 14] FIG. 14 is a side view of a filling device according to another exemplary embodiment. DETAILED DESCRIPTION OF THE INVENTION

[0012] Before turning to the figures which show in detail certain exemplary embodiments, it is to be understood that the present disclosure is not limited to the details or methods set forth in the description or shown in the drawings. It is to be understood that the terminology used herein is for the purpose of description only and should not be regarded as limiting.

[0013] As used herein, the terms "cured," "curing," "to cure," and the like refer to a material undergoing a chemical reaction to produce a crosslinked matrix in the rubber matrix. Curing can be accomplished chemically or by the application of heat or other energy sources. For example, vulcanization is a type of curing that involves the use of agents such as sulfur (among other types of agents).

[0014] As used herein, the term "pre-cured" refers to a material that has already been cured. Conversely, "uncured" refers to a material that is in its raw form and has not been cured. For example, curing an uncured material results in a cured, or pre-cured, material.

[0015] As used herein, the term "precured tire tread" refers to a tire tread or build-up (e.g., a blank, treadless precured product having no tread pattern thereon) that is separate from (e.g., not cured to) a tire carcass. After the precured tire tread is cured to the tire carcass, it becomes a tire tread, and the combination of the precured tire tread cured to the tire carcass forms the tire. The precured tire tread can be in the form of a strip, oval, circle, ring, or similar shape.

[0016] As used herein, the term "carcass" or "tire carcass" refers to the skeleton of a tire. The carcass includes all layers (e.g., rubber, reinforcing cords, etc.) that absorb the internal air pressure, weight, and shock associated with the operation of the tire.

[0017] As used herein, the term "anomaly" or "artifact" with respect to a tire carcass refers to an area on the tire carcass that may be repaired during the retreading process.

[0018] As used herein, the terms "skive" or "skiving" refer to the process of removing a portion of a tire carcass. Skiving prepares an abnormality on the tire carcass for repair. Skiving is completed by a rotary tool with a bit configured to remove tire carcass material (e.g., rubber, steel cord, etc.).

[0019] As used herein, the terms "axial" and "axially" refer to a direction that is parallel to an axis.

[0020] As used herein, the terms "radial" and "radially" refer to directions toward or away from the central axis.

[0021] As used herein, the terms "circumferential" or "circumferentially" refer to an arc along a round shape (eg, along the circumference of a circle).

[0022] When a tire is retreaded, the tire carcass is repaired first. A tire can also be repaired without being retreaded. During the repair process, at least a portion of the tire's tread is removed from the tire carcass. After removal of the portion, the tire carcass is inspected for features (e.g., damage, scuffs, anomalies, etc.) that will later be skived and filled with new rubber. If done manually, skiving and filling can be time-consuming, as each anomaly is skived and filled one at a time through a manual process. Methods and systems for more efficient filling of skived areas of a tire carcass are desirable during the manufacturing process and would also reduce labor in the process.

[0023] Referring now to FIG. 1 , a block diagram of a tire repair system 100 is shown, according to an exemplary embodiment. Tire repair system 100 may be used to complete a tire retreading process or a portion of a tire retreading process, such as repairing an anomaly in a tire carcass. In some embodiments, tire repair system 100 may be used to repair tires independent of a tire retreading process. Tire repair system 100 may be used to repair a variety of tires (e.g., summer tires, winter tires, heavy-duty tires, etc.) made from a variety of materials (e.g., synthetic rubber, natural rubber, textiles, wire, carbon black, etc.). In some embodiments, tire repair system 100 is included (e.g., integrated) in a manufacturing plant or assembly line.

[0024] The tire repair system 100 includes a computer system 102 (e.g., a controller). The computer system 102 controls the operation of the tire repair system 100. The components of the computer system 102 are operatively coupled to one another (e.g., via interconnections, wired connections, wireless connections, etc.) so that the components of the computer system 102 can send and receive signals to and from other components of the computer system 102. The computer system 102 includes a processor 104, a memory 106, a network device 108, an input device 110, an output device 112, and a number of sensors 114. In some embodiments, the processor 104 includes one or more microprocessors, application specific integrated circuits (ASICs), field programmable gate arrays (FPGAs), other forms of processing circuitry, or combinations thereof. The memory 106 stores data. For example, the memory 106 may include electrical, optical, magnetic, or any other storage or transmission device capable of providing program instructions to the processor 104. Memory 106 may include storage devices such as magnetic disks, memory chips, ROM, RAM, EEPROM, EPROM, flash memory, optical media, or any other suitable memory capable of providing instructions and / or data to processor 104. In some embodiments, memory 106 may include applications (e.g., computer programs designed to perform particular tasks) through which computer system 102 may be managed.

[0025] The computer system 102 further includes a network device 108. The network device 108 facilitates communication between the computer system 102 and external sources (e.g., computers, servers, mobile devices, etc.). The network device 108 may include a communication interface configured to send and receive signals and data through a wired connection (e.g., a local area network, etc.) or wirelessly (e.g., Wi-Fi, Bluetooth, etc.). The network device 108 enables the computer system 102 to send and receive signals or data from external sources. For example, operation of the network device 108 may include storing data on or receiving instructions from an external device (e.g., a server, mobile device, etc.). In some embodiments, the computer system 102 is connected only to associated devices and may operate with or without network connectivity.

[0026] The computer system 102 further includes an input device 110. The input device (input interface or user interface) 110 is configured to allow a user to input instructions into the computer system 102, which may allow the user to modify the operation of the tire repair system 100. The input device 110 is a device configured to enter commands into the computer system 102, such as a keyboard, mouse, touch screen, stylus, control panel, and similar input devices. In some embodiments, the input device 110 includes voice control. The computer system 102 also includes an output device 112, which is a device configured to display or communicate information, such as a monitor, audio system, light array, and similar output device. In some embodiments, the input device 110 and the output device 112 are the same device. For example, the input device 110 and the output device 112 may be a computer or computer tablet with integrated functionality for performing both input and output operations.

[0027] The computer system 102 further includes or comprises a plurality of sensors 114. For example, the computer system 102 may be configured to communicate with a sensor array including a plurality of sensors 114. The sensors 114 monitor the operation of the tire repair system 100. The sensors 114 may be optical sensors, temperature sensors, sound level meters, etc. In some embodiments, the computer system 102 is configured to modify the operation of the tire repair system 100 when one of the sensors 114 detects a non-compliant (e.g., out-of-compliance) condition, such as failure to meet predetermined criteria. For example, if the temperature of a component reaches a predetermined level indicating potential overheating, the computer system 102 may scale back operation of the tire repair system 100 to allow the component to cool. The tire repair system 102 may receive input from a temperature sensor at predetermined intervals, and if the temperature is exceeded, the operation of the tire repair system 100 may be modified to allow a predetermined cooling period, after which an iterative process may be performed in which information from the temperature sensor is then evaluated to determine whether operation can be restored to a previous state.

[0028] The tire repair system 100 further includes a repair component 116. The repair component 116 is operably coupled to the computer system 102 and configured to receive operational commands from the computer system 102. The computer system 102 controls and monitors the function of the repair component 116. The repair component 116 may be configured as hardware used to repair at least a portion of one or more tires. In particular, the repair component 116 includes devices configured to repair tires, and more specifically, to repair tire carcasses. For example, the repair component 116 may include a skiving device (skiver) and a filling device (filler). As described below, the repair component 116 may include additional components.

[0029] Referring now to FIG. 2 , a process diagram of a carcass repair system 200 is shown. The carcass repair system 200 is configured to analyze and repair a tire carcass. The carcass repair system 200 includes a damaged tire carcass 202. The damaged tire carcass 202 may be a used (e.g., operated on a vehicle) tire without tread. The damaged tire carcass 202 may be visibly damaged (e.g., chunking, scars, abrasions, punctures, etc.) or may have anomalies or artifacts that cannot be detected without a non-destructive detector (e.g., high-voltage x-ray technology, other detection technology, etc.). In some embodiments, the damaged tire carcass 202 may have minor anomalies or damage (e.g., generally not requiring repair or not requiring major repair), but passes through the tire repair system 100 as a precaution or as part of a predetermined process. In some embodiments, the carcass repair system 200 completes without input from a user. In some embodiments, the carcass repair system 200 is completed in a tire repair process area that is physically separate from other tire manufacturing processes.

[0030] The tire repair system 100 of Figure 2 includes a computer system 102 and a repair component 116. As described with reference to Figure 1, the computer system 102 includes components for controlling the operation of the tire repair system 100. In some embodiments, in addition to the skiving device and the filling device, the exemplary repair component may include additional components. For example, the repair component 116 includes a mandrel 204, a scanner 206, a skiving device 208, a vacuum 210, and a filling device 212.

[0031] The repair component 116 includes a mandrel (e.g., a rotatable hub, an expandable hub, etc.) 204 upon which the damaged tire carcass 202 may be placed. In some embodiments, the damaged tire carcass 202 may be a damaged tire with the tread still attached. The mandrel 204 is configured to receive the tire carcass 202 and selectively couple to the tire carcass 202 such that the damaged tire carcass 202 rotates with the mandrel 204. In some embodiments, the mandrel 204 does not rotate, but is coupled to the damaged tire carcass 202 such that the damaged tire carcass 202 does not rotate when subjected to a circumferential load. In some embodiments, the computer system 102 is operably coupled to the mandrel 204 and sends a rotation signal to a motor configured to rotate the mandrel 204. After the tire carcass 202 is placed on the mandrel 204, a scanner 206 scans the outer surface of the damaged tire carcass 202. The scanner 206 is configured to measure surface variations (e.g., artifacts, roughness, etc.) of the tire carcass 202 and transmit data corresponding to the measured variations to the computer system 102. The scanner 206 can be an optical scanner using image processing or a laser, or similar device capable of determining one or more surface characteristics of the damaged tire carcass 202. The computer system 102 receives the data from the scanner 206 and determines whether the damaged tire carcass 202 should be repaired. In some embodiments, the computer system 102 determines whether to repair the damaged tire carcass 202 according to a predetermined set of rules and / or parameters. In some embodiments, the computer system 102 includes an algorithm (e.g., machine learning, artificial intelligence, etc.) that determines whether to repair the damaged tire carcass 202 based on results from a training set. The data from the scanner 206 also includes location data that allows the computer system 102 to map the location of the damaged tire carcass 202 to be repaired.

[0032] In some embodiments, the computer system 102 mapping the location of the damaged tire carcass 202 to be repaired includes developing a 3D coordinate model of the damaged tire carcass 202. The 3D coordinate model may include overlays (e.g., coordinate layers, highlighted coordinates, coordinates assigned specific values, etc.) corresponding to areas of the damaged tire carcass 202 that have been determined to be repaired. In some embodiments, the computer system 102 creates a coordinate model of the areas of the tire carcass 202 to be repaired (e.g., only the portions of the carcass 202 that appear to require repair are modeled, and other areas of the carcass 202 are not modeled).

[0033] Once a determination is made as to whether the damaged tire carcass 202 should be repaired and the location of the area requiring repair is mapped, a skiving device 208 is used to skive the area of ​​the damaged tire carcass 202 to be repaired. The skiving device 208 includes a bit (e.g., a drill bit, a grinding bit, etc.) operably coupled to a rotary tool configured to remove a portion of the damaged tire carcass 202. In some embodiments, the skiving device 208 is a knife, a scoop device, or other device configured to remove a portion of the tire carcass. The skiving device 208 may be coupled to a robotic arm or similar positioning device. The skiving device 208 is controlled by the computer system 102. The computer system 102 sends a signal to the skiving device 208 including instructions that cause the skiving device 208 to remove the area of ​​the damaged tire carcass 202. In some embodiments, data received from the scanner 206 is used to determine the area of ​​the tire carcass 202 to be repaired. In some embodiments, the depth of the skived region is determined according to the size of the anomaly, hi some embodiments, the depth of the skived region is predetermined for each anomaly.

[0034] During operation of the skiving device 208, the vacuum 210 is configured to create a vacuum (e.g., a suction area corresponding to a negative pressure) in the area surrounding the skiving device 208. Use of the vacuum 210 reduces the likelihood of contamination of the surface of the damaged tire carcass 202 due to the operation of the skiving device 208. In some embodiments, the position of the vacuum 210 is repositioned during operation.

[0035] After the anomaly is skived by the skiving device 208, the skived area is filled with a filler material suitable for repairing the tire carcass by the filling device 212 (e.g., uncured rubber, synthetic rubber, natural rubber, pre-cured rubber, extruder rope, etc.). In some embodiments, the filling device 212 is a rubber extrusion gun or similar device configured to fill the skived area. In some embodiments, the filling device 212 is operably coupled to a robotic arm or similar positioning device configured to position an attachment at specific locations circumferentially around the damaged tire carcass 202 to fill the skived area on the damaged tire carcass 202. The filling device 212 is controlled by the computer system 102. The computer system 102 sends instructions to the filling device 212 including the location of the skived area, the depth of the skived area, and other information related to filling the skived area.

[0036] In some embodiments, the filling device 212 may fill a first skived area while the skiving device 208 skives a second skived area (e.g., a second artifact to be skived). The vacuum 210 is configured to suck the portion of the tire carcass 202 removed by the skiving device 208 so that the filling device 212 can operate simultaneously with the skiving device 208 without contaminating the unvulcanized rubber product provided by the filling device 212. The computer system 102 may use the data transmitted by the scanner 206 to determine the location to fill on the damaged tire carcass 202. In some embodiments, the filling device 212 dispenses a predetermined amount of material into each skived area, the predetermined amount being the same for each skived area. The predetermined amount may be a predetermined weight (e.g., 10 g, 20 g, 30 g, etc.) and / or a predetermined volume (e.g., 10 mL, 20 mL, 30 mL, 40 mL, 50 mL, etc.). In some embodiments, the filling device 212 dispenses an amount of material that corresponds to the characteristics (eg, depth, width, etc.) of the skived area.

[0037] For example, the scanner 206 is configured to detect one or more of the depth, axial width, and circumferential height of each skived region provided on the damaged tire carcass 202. Using one or more of the depth, axial width, and circumferential height of each skived region, the computer system 102 may determine the (e.g., approximate) volume of the skived region and send instructions to the filling device 212 to provide a similar volume of fill material. In some embodiments, the computer system 102 instructs the filling device 212 to provide a volume of fill material equal to an amount greater than the approximate volume of the skive (e.g., greater than about 100%, greater than about 110%, greater than about 120%, or greater than about 125%, or between about 100% and about 125% of the approximate volume). In some embodiments, the filling device 212 overfills the skived region (e.g., includes more material) to ensure that the skived region is sufficiently filled. In some embodiments, the computer system 102 may instruct the filling device 212 to provide a volume of fill material equal to 80% of the approximate volume of the skive. After filling each skived area, the damaged tire carcass 202 becomes a repaired tire carcass 214.

[0038] Referring now to FIG. 3 , a process diagram of a tire retreading method 300 is shown, according to an exemplary embodiment. The tire retreading method 300 begins with an initialization process 302, in which the tire is inspected and prepared for repair and retreading. At 304, a retreading facility receives used tires. The used tires may be damaged tires or tires that have been used on a vehicle. The used tires are then inspected at 306. This initial inspection may be performed manually by an operator. After the initial inspection, the used tires undergo electrical (e.g., non-destructive) testing at 308. The electrical testing uses high voltage to identify abnormalities in the used tires. In some embodiments, the locations of the abnormalities identified by the electrical testing may be stored in computer memory and may be accessed at a later time. The used tires undergo additional inspection at 310. At 310, shearography testing (e.g., speckle pattern shearing interferometry) is used to determine whether there are any non-conforming areas within the used tires. In some embodiments, a method that includes performing an inspection using both shearography techniques and applied voltage improves the accuracy of determining whether one or more non-conforming areas are present in the sidewall and / or tread of a tire.

[0039] In some embodiments, the locations of anomalies identified during shearography are stored in computer memory and can be accessed at a later time. After the used tire is inspected, the surface is buffed at 312. During buffing, the tire tread is removed from the tire so that only the bare tire carcass remains, such as damaged tire carcass 202. Buffing prepares the tire carcass for repair in carcass repair system 200. Carcass repair system 200 may use the same repair process for all types of tires or may be specifically tailored for the type of tire being repaired (e.g., size, material, etc.).

[0040] After repairing the tire carcass at 200, the tire carcass is retreaded during a tire retreading process 318. At 320, a rubber cushion (e.g., a material used to adhere a tread to a tire carcass) is applied to the tire carcass. In some embodiments, the rubber cushion is thick enough to fill any portions of the tire carcass that may have been underfilled by the carcass repair system 200. Once the rubber cushion is applied, the tire carcass is assembled at 322 by applying a tire tread over the cushion rubber to form an uncured tire. At 324, an envelope is applied to the uncured tire to seal the tire tread to the tire carcass. The uncured tire is then cured at 326. After the tire is cured, the tire is finally inspected at 328. If the inspection passes, the tire is deemed suitable for operation / use. Thus, the carcass repair system 200 can help resolve any issues that affect whether the tire passes inspection.

[0041] 4, in some embodiments, method 400 may be performed sequentially. Sequential method 400 may be performed by computer system 102 such that each step is completed automatically and multiple steps may be performed without user input. For example, each step may be completed by a robotic device associated with a component that receives instructions from computer system 102. In some embodiments, a user inputs instructions to computer system 102 for one or more steps. In some embodiments, computer system 102 may be partially automated such that a user provides initial input and then one or more steps of method 400 may be performed automatically without further user involvement.

[0042] At 402, a tire carcass, such as tire carcass 202, is placed on a mandrel, such as mandrel 204. The tire carcass may be placed on the mandrel by a robotic arm or a user. The mandrel is then coupled to the tire carcass. At 404, the repair area is identified by scanner 206 (e.g., by identifying surface characteristics that differ from surrounding areas). In some embodiments, identification of the area to be repaired is accomplished prior to 402, and computer system 102 reads the previously identified data at 404. At 406, computer system 102 maps the identified area. The mapped area is then stored in memory 106 of computer system 102. Mapping includes creating a three-dimensional model of the tire carcass and the corresponding identified area. Mapping enables computer system 102 to instruct skiving device 208 and filling device 212 to skive and fill the identified area.

[0043] At 408, the computer system 102 sends instructions to the skiving device 208 to skive the mapped areas. The computer system 102 generates a skiving path (e.g., a tool path) based on one or more of the locations of the identified areas. In some embodiments, the skiving path is determined as the shortest route for the skiving device 208 to skive all of the identified areas.

[0044] At 410, the computer system 102 commands the filling device 212 to fill the skived regions. In some embodiments, the same robotic arm operates the skiving device 208 and the filling device 212. For example, the robotic arm may be controlled to couple to the skiving device 208, skive the mapped regions, and then detach from the skiving device 208. After detaching the skiving device 208, the robotic arm may be controlled to couple to the filling device 212. The filling device 212 can sequentially follow the skiving path determined by the computer system 102. In some embodiments, the computer system 102 establishes the filling path based on the skived regions. The filling path may also include information corresponding to the amount of material to be deposited by the filling device 212 in each region. In some embodiments, the filling path may be adjusted for efficiency so that the filling path is completed in the shortest time possible. For example, the fill path may direct the robotic arm to position the fill device to fill each skived area circumferentially around the tire carcass in sequence, thereby reducing the distance between each fill process. After filling each skived area, the tire carcass is removed from the mandrel 204 at 412 and retreading continues.

[0045] Referring to FIG. 5 , a process diagram of a method 500 for using carcass repair system 200 is shown. Method 500 uses simultaneous skiving and filling of a tire carcass, such as tire carcass 202, to increase the efficiency of carcass repair system 200 compared to sequential method 400. In some embodiments, simultaneous method 500 is preferred over sequential method 400 because simultaneous method 500 can be more efficient than sequential method 400, thereby reducing the amount of time required for tire retreading process 318. Simultaneous method 500 can be controlled by computer system 102 such that each step is completed automatically without user input. For example, each step can be completed by a robotic device associated with a component that receives instructions from computer system 102. In some embodiments, a user inputs instructions into computer system 102 for each step. In some embodiments, computer system 102 can switch between sequential method 400 and simultaneous method 500 depending on the particular situation (e.g., the size of the tire carcass, the severity of damage to the carcass, etc.). A user may also input signals into the computer system 102 to select or switch between methods, for example, depending on a setting or configuration.

[0046] At 502, a tire carcass is loaded onto a mandrel, such as mandrel 204. The tire carcass may be loaded by a robotic arm or a user. The mandrel 204 is then coupled to the tire carcass. At 504, the area to be repaired is identified by scanner 206. In some embodiments, the identification is performed prior to this step, with computer system 102 reading the previously identified data at 504. At 506, the identified area is mapped. Mapping is completed by computer system 102, which then stores the mapped area in memory 106 of computer system 102. Mapping includes creating a three-dimensional model of the tire carcass and the corresponding identified area. Mapping allows computer system 102 to instruct skiving device 208 and filling device 212 to skive and fill the correct areas.

[0047] At 508, the computer system 102 sends instructions to the skiving device 208 to skive the mapped areas. The computer system 102 generates a skiving path based on the location of the identified areas. In some embodiments, the skiving path is determined as the shortest route for the skiving device 208 to skive all of the identified areas. At 510, the computer system 102 and the skiving device 208 continue to follow the skiving path. Simultaneously, the computer system 102 sends instructions to the filling device 212 to fill the areas skived by the skiving device 208. The computer system 102 generates a fill path. This path may be determined as the shortest route (shortest path) for the filling device 212 to fill all of the skived areas. In some embodiments, the fill path is the same as the skiving path, but with a delay to prevent the skiving device 208 and the filling device 212 from interfering with each other during operation. Thus, the delay acts as a lag between the operation of the skiving device 208 and the operation of the filling device 212. The delay can be a step delay (e.g., the filling device 212 fills the area immediately after skiving). The step delay prevents the filling device 212 from interfering with the operation of the skiving device 208. In other words, the delay is to ensure that there is no overlap between the filling and skiving from the filling device 212 and the skiving device 208, respectively. In some embodiments, the delay is a time delay, and the filling device 212 waits a predetermined amount of time (e.g., 1 second, 2 seconds, 3 seconds, 4 seconds, 5 seconds, etc.). Waiting the predetermined amount of time allows the skived area to cool prior to filling.

[0048] At 514, the relative positions of the tire carcass, the skiving device 208, and the filling device 212 are repositioned. In some embodiments, the repositioning includes rotating the tire carcass on the mandrel 204. In some embodiments, the repositioning includes changing the position of the skiving device 208 and the filling device 212. For example, if the skiving device 208 and the filling device 212 are coupled to a robotic arm, the position of the robotic arm may be repositioned. The computer system 102 controls the repositioning by sending instructions to components of the tire repair system 100 associated with the repositioning. In some embodiments, the repositioning is performed automatically during steps 510 and 512. At 516, the computer system 102 determines whether all mapped areas of the tire carcass have been skived and subsequently filled. In some embodiments, this determination corresponds to whether the skiving and filling paths are complete. In some embodiments, the tire carcass is further scanned to determine whether the tire carcass has been completely repaired. If it is determined at 516 that the tire carcass should be repaired, then at 518 the tire carcass is removed from the mandrel 204 .

[0049] Referring to FIG. 6 , a cross-sectional view of a tire carcass, such as damaged tire carcass 202, is shown. The damaged tire carcass 202 has been skived and includes a skived region 600, which is a recess in the tire carcass surface 602. The skived region 600 has a skive depth 604 relative to the tire carcass surface 602. The skived region 600 also has a skive width 606, which corresponds to the maximum distance between two points of the skived region 600 that are flush with the tire carcass surface 602. In some embodiments, the skive depth 604 and the skive width 606 vary depending on the skiving device 208, the size of the skived defect, and other similar factors. In some embodiments, the completely damaged tire carcass 202 includes multiple skived regions 600 after skiving.

[0050] Referring to FIG. 7 , a cross-sectional view of the tire carcass of FIG. 6 is shown after filling of the skived areas 600. Filling includes filling the skived areas 600 of the damaged tire carcass 202 with an amount of material to form a filled area 700. The skived areas 600 are filled by the filling device 212 as directed by the computer system 102. The amount of material deposited by the filling device 212 may depend on the shape and size of the skived area (e.g., skive depth 604 and skive width 606). For example, the computer system 102 may determine the volume of material needed to fill the skived areas 600 and then send instructions to the filling device 212 to deposit the required volume of material. In some embodiments, the computer system 102 sends instructions to the filling device 212 to deposit an equal amount of material into each skived area 600.

[0051] In some embodiments, the filling of the filling region 700 is flush with the tire carcass surface 602. In some embodiments, the filling region 700 is overfilled (e.g., extends above the tire carcass surface 602). The overfilling can ensure that the skived region 600 is completely filled. However, in some embodiments, the filling region 700 can be underfilled (e.g., below the tire carcass surface 602).

[0052] Referring to FIG. 8 , a process diagram of a fill determination method 800 is shown. In some embodiments, not all of the skived areas 600 of the damaged tire carcass 202 are filled. For example, shallow areas (e.g., having a shallow skive depth 604) may be filled with cushion gum downstream of the carcass repair system 200. The fill determination method 800 is controlled by the computer system 102. The fill determination method 800 determines areas of the damaged tire carcass 202 to fill. Determining the areas to fill may improve the efficiency of the carcass repair process. For example, not performing fill on shallow areas that could be filled with cushion gum may reduce the overall repair time.

[0053] At 802, an area to be filled is identified. This area may be an area mapped for skiving, or this area may be an area determined by the scanner 206. Once the area is identified, the computer system 102 determines whether the depth of the identified area (e.g., skive depth 604) is deeper than a predetermined threshold. The predetermined threshold may be the maximum depth to which cushion gum can be filled during the retreading process. If the identified area is not deeper than the predetermined threshold, the fill determination method 800 returns to 802 to identify another area. If, at 804, it is determined that the identified area is deeper than the predetermined threshold, then, at 806, the area is mapped by the computer system 102. While mapping the area at 806, the computer system 102 may generate one or more fill paths.

[0054] At 810, the computer system 102 determines whether each of the regions previously identified at 802 has been mapped. If not, the additional regions identified at 802 are mapped. If all regions have been identified, the fill determination method 800 proceeds to 812. At 812, the fill path is followed to fill all of the mapped regions.

[0055] 9-14, exemplary embodiments of tire repair system 100 and components of tire repair system 100 are shown. In some embodiments, tire repair system 100 is reconfigured for a different type of tire. In some embodiments, components of tire repair system 100 are replaced with similar components. In some embodiments, components of tire repair system 100 are used for additional processes outside of the tire repair process. FIGS. 9, 11, 12, and 13 show a robotic arm 900. In some embodiments, this robotic arm 900 may be used for several different processes or may be specialized for one process. In some embodiments, tire repair system 100 includes two or more robotic arms 900. In some embodiments, the robotic arms are industrial robots configured to assume various positions. For example, the head of the industrial robot may be selectively positioned in x, y, and z coordinate space by one or more servo mechanisms.

[0056] 9, the repair component 116 is shown according to an exemplary embodiment. The robotic arm 900 is configured to position the damaged tire carcass 202 on the mandrel 204. Once the damaged tire carcass 202 is positioned on the mandrel 204, the mandrel arm 902 expands to couple the damaged tire carcass 202 to the mandrel 204. This process can be reversed when removing the tire carcass from the mandrel 204.

[0057] Referring to Figure 10, the repair component 116 is shown, according to an exemplary embodiment. Figure 10 illustrates a scanning operation. The scanning may be performed by an optical scanner (e.g., the scanner 206 shown in Figure 2) that uses a laser 1000 to scan the tire carcass surface 602 of the damaged tire carcass 202. In some embodiments, the scanner 206 is in a fixed position relative to the mandrel 204, and the mandrel 204 rotates the damaged tire carcass 202 so that the scanner 206 scans the entire damaged tire carcass 202. The computer system 102 analyzes the data generated by the scanner 206 to determine the areas of the damaged tire carcass 202 to repair.

[0058] 11 , a diagram of a skiving device 208 coupled to a robotic arm 900 is shown skiving a damaged tire carcass 202 coupled to a mandrel 204. A vacuum 210 removes (e.g., by applying negative pressure) any contaminants created by skiving the tire carcass 202. The mandrel 204 can rotate the damaged tire carcass 202 so that the skiving device 208 can skive any location on the surface of the damaged tire carcass 202 without having to move circumferentially around the tire carcass 202. In some embodiments, the robotic arm 900 repositions the skiving device 208 circumferentially around the damaged tire carcass 202 while the tire carcass is being rotated by the mandrel. In some embodiments, the mandrel 204 and the robotic arm 900 operate in conjunction (e.g., simultaneously) to position the damaged tire carcass 202 and the skiving device 208. In some embodiments, the skiving device 208 of FIG. 11 is replaced with a filling device, such as filling device 212.

[0059] 12 , a diagram of tool selection is shown. The computer system 102 is configured to send instructions to the robotic arm 900 to selectively couple to one of various tools 1200 positioned within the x, y, z coordinate space of the robotic arm 900. The various tools 1200 may include a filling device 212 and a skiving device 208. The ability to selectively couple allows a single robotic arm 900 to operate various tools that may be used for different operations during the skiving and / or filling process. For example, the robotic arm 900 may be operated by the computer system 102 to first couple to the skiving device 208, skive a damaged area of ​​the tire carcass 202, separate from the skiving device 208, couple to the filling device 212, and then fill the skived area 600. It should be understood that other intermediate or finishing operations may be performed according to various embodiments.

[0060] 13 , a side view of the filling device 212 is shown, according to an exemplary embodiment. The filling device 212 is operably coupled to a robotic arm 900. The robotic arm 900 is configured to position the filling device 212 relative to the damaged tire carcass 202 such that the filling device 212 can provide uncured rubber material to the tire carcass surface 602 of the damaged tire carcass 202.

[0061] 14 , a side view of a filling device 212 is shown, according to another exemplary embodiment. The filling device 212 is coupled (e.g., operatively coupled, slidably coupled, etc.) to a positioning rail 1400. The positioning rail 1400 is configured to position the filling device 212 circumferentially around the tire carcass. In some embodiments, the filling device 212 is slidably coupled to the positioning rail 1400 and configured to translate circumferentially around the damaged tire carcass 202, such as by a linear bearing. The positioning rail 1400 is further configured to allow the filling device 212 to translate axially relative to the surface of the damaged tire carcass 202.

[0062] It should be noted that the use of the term "exemplary" and variations thereof in this specification to describe various embodiments is intended to indicate that such embodiments are possible examples, representations, or illustrations of possible embodiments (and such terms are not intended to imply that such embodiments are necessarily particular or best examples).

[0063] As used herein, the term "coupled" and variations thereof mean joining two members directly or indirectly to one another. Such joining can be static (e.g., permanent or fixed) or movable (e.g., removable or releasable). Such joining can be achieved by two members directly joined to one another, by two members joined to one another using a separate intervening member joined to one another and any additional intermediate member joined to the other, or by two members joined to one another using an intervening member integrally formed as a single unit with one of the two members. When "coupled" or variations thereof are modified by additional terms (e.g., directly coupled), the general definition of "coupled" provided above is modified by the plain language meaning of the additional terms (e.g., "directly coupled" means joining two members without a separate intervening member), resulting in a definition narrower than the general definition of "coupled" provided above. Such joining can be mechanical, electrical, or fluid.

[0064] References to the location of elements herein (e.g., "top," "bottom," "upper," "lower") are used merely to describe the orientation of the various elements in the figures. It should be noted that the orientation of the various elements may differ in other exemplary embodiments, and such variations are intended to be encompassed by the present disclosure.

[0065] The hardware and data processing components used to implement the various processes, operations, exemplary logic, logic blocks, modules, and circuits described in connection with the embodiments disclosed herein may be implemented or performed by general-purpose single-chip or multi-chip processors, digital signal processors (DSPs), application-specific integrated circuits (ASICs), field-programmable gate arrays (FPGAs) or other programmable logic devices, discrete gate or transistor logic, discrete hardware components, or any combination thereof designed to perform the functions described herein. A general-purpose processor may be a microprocessor, or any conventional processor, controller, microcontroller, or state machine. A processor may also be implemented as a combination of computing devices, such as a combination of a DSP and a microprocessor, multiple microprocessors, one or more microprocessors in conjunction with a DSP core, or any other such configuration. In some embodiments, particular processes and methods may be performed by circuitry specific to a given function. Memory (e.g., memory, memory unit, storage device) may include one or more devices (e.g., RAM, ROM, flash memory, hard disk storage) for storing data and / or computer code to complete or facilitate the various processes, layers, and modules described in this disclosure. The memory may be or include volatile or non-volatile memory and may include database components, object code components, script components, or any other type of information structure for supporting the various activities and information structures described in this disclosure. According to an exemplary embodiment, the memory is communicatively coupled to the processor via a processing circuit and includes computer code for executing (e.g., by the processing circuit or processor) one or more processes described herein.

[0066] The present disclosure contemplates methods, systems, and program products on any machine-readable media for accomplishing various operations. Embodiments of the present disclosure may be implemented using existing computer processors, by dedicated computer processors for suitable systems incorporated for this or other purposes, or by hardwired systems. Embodiments within the scope of the present disclosure include program products comprising machine-readable media for carrying or having machine-executable instructions or stored data structures. Such machine-readable media may be any available medium that can be accessed by a general-purpose or special-purpose computer or other machine with a processor. By way of example, such machine-readable media may comprise RAM, ROM, EPROM, EEPROM, or other optical disk storage, magnetic disk storage, or other magnetic storage devices, or any other medium that can be used to carry or store desired program code in the form of machine-executable instructions or data structures and that can be accessed by a general-purpose or special-purpose computer or other machine with a processor. Combinations of the above are also included within the scope of machine-readable media. Machine-executable instructions include, for example, instructions and data that cause a general-purpose computer, special-purpose computer, or special-purpose processing machine to perform a certain function or group of functions.

[0067] While the figures and descriptions may indicate a particular order of method steps, the order of such steps may differ from that depicted and described unless otherwise specified above. Also, two or more steps may be performed concurrently or with partial concurrence unless otherwise specified above. Such variations may depend, for example, on the software and hardware systems selected and designer choice. All such variations are within the scope of this disclosure. Similarly, software implementations of the described methods may be achieved using standard programming techniques, including rule-based logic and other logic to accomplish the various connecting, processing, comparing, and decision steps.

[0068] It is important to note that the construction and configuration of the systems shown in the various exemplary embodiments are exemplary only. Additionally, any element disclosed in one embodiment may be incorporated into or used in any other embodiment disclosed herein. For example, the positioning rail of the exemplary embodiment described with reference to FIG. 14 may be incorporated into the method of the exemplary embodiment described with reference to at least FIG. 5. While only one example of an element from one embodiment that may be incorporated into or used in another embodiment is described above, it should be understood that other elements of various embodiments may be incorporated into or used in any of the other embodiments disclosed herein.

Claims

1. 1. A system for automatically filling a skived area on a tire carcass, the system comprising: A scanner and a filling device; a circumferential rail extending circumferentially around the tire carcass, the filling device being coupled to the circumferential rail and translating along the surface of the tire carcass along the circumferential rail; a controller communicatively coupled to the scanner and the filling device, the controller comprising a processor and a memory configured to store instructions that cause the controller to perform operations, the operations including: analyzing a surface of the tire carcass using the scanner; identifying a first skived region and a second skived region of the tire carcass; Determining whether to perform filling of the first skived region and the second skived region; Generating a filling path to fill the first skived area and the second skived area so that the filling path is the shortest path; and a controller instructing the filling device to fill the first skived area and the second skived area based on the fill path.

2. 2. The system of claim 1, wherein the filling device is operably coupled to an industrial robot having a robotic arm configured to position the filling device circumferentially around the surface of the tire carcass when the tire carcass is operably coupled to the system.

3. The instructions further include causing the controller to: Positioning the filling device against the tire carcass; The system of claim 1 , wherein the filling device is translated circumferentially and axially around the tire carcass.

4. The instructions further include causing the controller to: determining a first depth of the first skived region; determining whether the first depth of the first skived region is greater than a predetermined depth threshold; 2. The system of claim 1, further comprising: instructing the filling device to fill the first skived region in response to determining that the first depth of the first skived region is greater than the predetermined depth threshold.

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